System for Lining a Wellbore Casing

ABSTRACT

A system for lining a wellbore casing includes a support member, an expansion device coupled to an end of the support member, and a tubular liner coupled to the expansion device. The tubular liner includes an expandable tubular member that includes a first tubular portion, a second tubular portion, and an intermediate tubular portion coupled between the first and second tubular portions. The expandable tubular member also includes a sealing member coupled to the exterior surface of the intermediate tubular portion.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage filing for PCT patentapplication serial number PCT/US02/25727, attorney docket number25791.67.03, filed on Aug. 14, 2002, which claimed the benefit of thefiling dates of U.S. provisional patent application Ser. No. 60/317,985,attorney docket no. 25791.67, filed on Sep. 6, 2001, and U.S.provisional patent application Ser. No. 60/318,386, attorney docket no.25791.67.02, filed on Sep. 10, 2001, the disclosures of which areincorporated herein by reference.

The present application is a continuation-in-part of U.S. utility patentapplication Ser. No. 10/030,593, attorney docket number 25791.25.08,filed on Jan. 8, 2002, which was the National Stage filing for PCTpatent application serial number PCT/US00/18635, attorney docket no.25791.25.02, filed on Jul. 9, 2000, which claimed the benefit of thefiling dates of U.S. provisional patent application Ser. No. 60/146,203,attorney docket no. 25791.25, filed on Jul. 29, 1999, and U.S.provisional patent application Ser. No. 60/143,039, attorney docket no.25791.26, filed on Jul. 9, 1999, the disclosures of which areincorporated herein by reference.

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No.6,695,012, the disclosures of which are incorporated herein byreference.

BACKGROUND

This invention relates generally to wellbore casings, and in particularto wellbore casings that are formed using expandable tubing.

Conventionally, when a wellbore is created, a number of casings areinstalled in the borehole to prevent collapse of the borehole wall andto prevent undesired outflow of drilling fluid into the formation orinflow of fluid from the formation into the borehole. The borehole isdrilled in intervals whereby a casing which is to be installed in alower borehole interval is lowered through a previously installed casingof an upper borehole interval. As a consequence of this procedure thecasing of the lower interval is of smaller diameter than the casing ofthe upper interval. Thus, the casings are in a nested arrangement withcasing diameters decreasing in downward direction. Cement annuli areprovided between the outer surfaces of the casings and the borehole wallto seal the casings from the borehole wall. As a consequence of thisnested arrangement a relatively large borehole diameter is required atthe upper part of the wellbore. Such a large borehole diameter involvesincreased costs due to heavy casing handling equipment, large drill bitsand increased volumes of drilling fluid and drill cuttings. Moreover,increased drilling rig time is involved due to required cement pumping,cement hardening, required equipment changes due to large variations inhole diameters drilled in the course of the well, and the large volumeof cuttings drilled and removed.

The present invention is directed to overcoming one or more of thelimitations of the existing procedures for forming wellbore casings.

SUMMARY

According to one aspect of the present invention, a system for lining awellbore casing is provided that includes a tubular support memberdefining a first passage, a tubular expansion cone defining a secondpassage fluidicly coupled to the first passage coupled to an end of thetubular support member and comprising a tapered end, a tubular linercoupled to and supported by the tapered end of the tubular expansioncone, and a shoe defining a valveable passage coupled to an end of thetubular liner, wherein the tubular liner includes one or more expandabletubular members that each include a tubular body comprising anintermediate portion and first and second expanded end portions coupledto opposing ends of the intermediate portion, and a sealing membercoupled to the exterior surface of the intermediate portion, and one ormore other tubular members coupled to the expandable tubular members,wherein the inside diameters of the other tubular members are greaterthan or equal to the outside diameter of the tubular expansion cone.

According to another aspect of the present invention, a method of lininga wellbore casing is provided that includes positioning a tubular linerwithin the wellbore casing, and radially expanding one or more discreteportions of the tubular liner into engagement with the wellbore casing.

According to another aspect of the present invention, a system forlining a wellbore casing is provided that includes means for positioninga tubular liner within the wellbore casing, and means for radiallyexpanding one or more discrete portions of the tubular liner intoengagement with the wellbore casing. In an exemplary embodiment, aplurality of discrete portions of the tubular liner are radiallyexpanded into engagement with the wellbore casing.

According to another aspect of the present invention, an apparatus isprovided that includes a subterranean formation defining a borehole, acasing positioned in and coupled to the borehole, and a tubular linerpositioned in and coupled to the casing at one or more discretelocations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a cross sectional illustration of the placement of anillustrative embodiment of a system for lining a wellbore casing withina borehole having a preexisting wellbore casing.

FIG. 1 b is a cross sectional illustration of the system of FIG. 1 aduring the injection of a fluidic material into the tubular supportmember.

FIG. 1 c is a cross sectional illustration of the system of FIG. 1 bduring the pressurization of the interior portion of the shoe aftersealing off the valveable fluid passage of the shoe.

FIG. 1 d is a cross sectional illustration of the system of FIG. 1 cduring the continued injection of the fluidic material into the tubularsupport member.

FIG. 1 e is a cross sectional illustration of the system of FIG. 1 dafter the completion of the radial expansion and plastic deformation ofthe expandable tubular members.

FIG. 1 f is a cross sectional illustration of the system of FIG. 1 eafter machining the bottom central portion of the shoe.

FIG. 2 is a cross sectional illustration of an illustrative embodimentof the expandable tubular members of the system of FIG. 1 a.

FIG. 3 is a flow chart illustration of an illustrative embodiment of amethod for manufacturing the expandable tubular member of FIG. 2.

FIG. 4 a is a cross sectional illustration of an illustrative embodimentof the upsetting of the ends of a tubular member.

FIG. 4 b is a cross sectional illustration of the expandable tubularmember of FIG. 4 a after radially expanding and plastically deformingthe ends of the expandable tubular member.

FIG. 4 c is a cross sectional illustration of the expandable tubularmember of FIG. 4 b after forming threaded connections on the ends of theexpandable tubular member.

FIG. 4 d is a cross sectional illustration of the expandable tubularmember of FIG. 4 c after coupling sealing members to the exteriorsurface of the intermediate unexpanded portion of the expandable tubularmember.

FIG. 5 is a cross-sectional illustration of an exemplary embodiment of atubular expansion cone.

FIG. 6 is a cross-sectional illustration of an exemplary embodiment of atubular expansion cone.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially to FIG. 1 a, the reference numeral 10 refers, ingeneral, to a system for lining a wellbore casing that includes atubular support member 12 that defines a passage 12 a. A tubularexpansion cone 14 that defines a passage 14 a is coupled to an end ofthe tubular support member 12. In an exemplary embodiment, the tubularexpansion cone 14 includes a tapered outer surface 14 b for reasons tobe described. A pre-expanded end 16 a of a first expandable tubularmember 16 that defines a passage 16 b is adapted to mate with and besupported by the tapered outer surface 14 b of the tubular expansioncone 14. The first expandable tubular member 16 further includes anunexpanded intermediate portion 16 c, another pre-expanded end 16 d, anda sealing member 16 e coupled to the exterior surface of the unexpandedintermediate portion. In an exemplary embodiment, the inside and outsidediameters of the pre-expanded ends, 16 a and 16 d, of the firstexpandable tubular member 16 are greater than the inside and outsidediameters of the unexpanded intermediate portion 16 c. An end 18 a of ashoe 18 that defines a passage 18 b and a valveable passage 18 c iscoupled to the pre-expanded end 16 a of the first expandable tubularmember 16 by a conventional threaded connection.

An end 20 a of a tubular member 20 that defines a passage 20 b iscoupled to the other pre-expanded end 16 d of the first expandabletubular member 16 by a conventional threaded connection. Another end 20c of the tubular member 20 is coupled to an end 22 a of a tubular member22 that defines a passage 22 b by a conventional threaded connection. Apre-expanded end 24 a of a second expandable tubular member 24 thatdefines a passage 24 b is coupled to the other end 22 c of the tubularmember 22. The second expandable tubular member 24 further includes anunexpanded intermediate portion 24 c, another pre-expanded end 24 d, anda sealing member 24 e coupled to the exterior surface of the unexpandedintermediate portion. In an exemplary embodiment, the inside and outsidediameters of the pre-expanded ends, 24 a and 24 d, of the secondexpandable tubular member 24 are greater than the inside and outsidediameters of the unexpanded intermediate portion 24 c.

An end 26 a of a tubular member 26 that defines a passage 26 b iscoupled to the other pre-expanded end 24 d of the second expandabletubular member 24 by a conventional threaded connection. Another end 26c of the tubular member 26 is coupled to an end 28 a of a tubular member28 that defines a passage 28 b by a conventional threaded connection. Apre-expanded end 30 a of a third expandable tubular member 30 thatdefines a passage 30 b is coupled to the other end 28 c of the tubularmember 28. The third expandable tubular member 30 further includes anunexpanded intermediate portion 30 c, another pre-expanded end 30 d, anda sealing member 30 e coupled to the exterior surface of the unexpandedintermediate portion. In an exemplary embodiment, the inside and outsidediameters of the pre-expanded ends, 30 a and 30 d, of the thirdexpandable tubular member 30 are greater than the inside and outsidediameters of the unexpanded intermediate portion 30 c.

In an exemplary embodiment, the inside and outside diameters of thepre-expanded ends, 16 a, 16 d, 24 a, 24 d, 30 a and 30 d, of theexpandable tubular members, 16, 24, and 30, and the tubular members 20,22, 26, and 28, are substantially equal. In several exemplaryembodiments, the sealing members, 16 e, 24 e, and 30 e, of theexpandable tubular members, 16, 24, and 30, respectively, furtherinclude anchoring elements for engaging the wellbore casing 104. Inseveral exemplary embodiments, the tubular members, 20, 22, 26, and 28,are conventional tubular members having threaded end connectionssuitable for use in an oil or gas well, an underground pipeline, or as astructural support.

In an exemplary embodiment, as illustrated in FIG. 1 a, the system 10 isinitially positioned in a borehole 100 formed in a subterraneanformation 102 that includes a pre-existing wellbore casing 104. Theborehole 100 may be positioned in any orientation from vertical tohorizontal. Furthermore, the wellbore casing 104 may be, for example, awellbore casing for an oil or gas well, an underground pipeline, or astructural support. In an exemplary embodiment, the upper end of thetubular support member 12 may be supported in a conventional mannerusing, for example, a slip joint, or equivalent device in order topermit upward movement of the tubular support member and tubularexpansion cone 14 relative to one or more of the expandable tubularmembers, 16, 24, and 30, and tubular members, 20, 22, 26, and 28.

In an exemplary embodiment, as illustrated in FIG. 1 b, a fluidicmaterial 106 is then injected into the system 10, through the passages,12 a and 14 a, of the tubular support member 12 and tubular expansioncone 14, respectively. The fluidic material 106 then passes into thepassages, 18 b and 18 c, of the shoe 18 into the borehole 100.

In an exemplary embodiment, as illustrated in FIG. 1 c, a ball 108, plugor other equivalent device is then introduced into the injected fluidicmaterial 106. The ball 108 will then pass through the passages, 12 a, 14a, and 18 b, of the tubular support member 12, the tubular expansioncone 14, and the shoe 18, respectively, and will then be positionedwithin the valveable passage 18 c of the shoe. In this manner, thevalveable passage 18 c of the shoe 18 is closed thereby permitting thepassage 18 b of the shoe below the tubular expansion cone 14 to bepressurized by the continued injection of the fluidic material 106.

In an exemplary embodiment, as illustrated in FIG. 1 d, the continuedinjection of the fluidic material 106 through the passages, 12 a and 14a, of the tubular support member 12 and the tubular expansion cone 14,respectively, pressurizes the passage 18 b of the shoe 18 below thetubular expansion cone thereby radially expanding and plasticallydeforming the expandable tubular member 16 off of the tapered externalsurface 14 b of the tubular expansion cone 14. In particular, theintermediate non pre-expanded portion 16 c of the expandable tubularmember 16 is radially expanded and plastically deformed off of thetapered external surface 14 b of the tubular expansion cone 14. As aresult, the sealing member 16 e engages the interior surface of thewellbore casing 104. Consequently, the radially expanded intermediateportion 16 c of the expandable tubular member 16 is thereby coupled tothe wellbore casing 104. In an exemplary embodiment, the radiallyexpanded intermediate portion 16 c of the expandable tubular member 16is also thereby anchored to the wellbore casing 104.

The continued injection of the fluidic material 106 through thepassages, 12 a and 14 a, of the tubular support member 12 and thetubular expansion cone 14, respectively, will then displace the tubularexpansion cone 14 upwardly into engagement with the pre-expanded end 24a of the second expandable tubular member 24.

In an exemplary embodiment, as illustrated in FIG. 1 e, the continuedinjection of the fluidic material 106 through the passages, 12 a and 14a, of the tubular support member 12 and tubular expansion cone 14,respectively, will then pressurize the passages 18 b, 16 b, 20 b and 22b below the tubular expansion cone thereby radially expanding andplastically deforming the second expandable tubular member 24 off of thetapered external surface 14 b of the tubular expansion cone 14. Inparticular, the intermediate non pre-expanded portion 24 c of the secondexpandable tubular member 24 is radially expanded and plasticallydeformed off of the tapered external surface 14 b of the tubularexpansion cone 14. As a result, the sealing member 24 e engages theinterior surface of the wellbore casing 104. Consequently, the radiallyexpanded intermediate portion 24 c of the second expandable tubularmember 24 is thereby coupled to the wellbore casing 104. In an exemplaryembodiment, the radially expanded intermediate portion 24 c of thesecond expandable tubular member 24 is also thereby anchored to thewellbore casing 104.

The continued injection of the fluidic material 106 through thepassages, 12 a and 14 a, of the tubular support member 12 and thetubular expansion cone 14, respectively, will then displace the tubularexpansion cone 14 upwardly into engagement with the pre-expanded end 30a of the third expandable tubular member 30.

The continued injection of the fluidic material 106 through thepassages, 12 a and 14 a, of the tubular support member 12 and tubularexpansion cone 14, respectively, will then pressurize the passages 18 b,16 b, 20 b, 22 b, 24 b, 26 b, and 28 b below the tubular expansion conethereby radially expanding and plastically deforming the thirdexpandable tubular member 30 off of the tapered external surface 14 b ofthe tubular expansion cone 14. In particular, the intermediate nonpre-expanded portion 30 c of the third expandable tubular member 30 isradially expanded and plastically deformed off of the tapered externalsurface 14 b of the tubular expansion cone 14. As a result, the sealingmember 30 e engages the interior surface of the wellbore casing 104.Consequently, the radially expanded intermediate portion 30 c of thethird expandable tubular member 30 is thereby coupled to the wellborecasing 104. In an exemplary embodiment, the radially expandedintermediate portion 30 c of the third expandable tubular member 30 isalso thereby anchored to the wellbore casing 104.

In an exemplary embodiment, during the injection of the fluidic material106 through the passages, 12 a and 14 a, of the tubular support member12 and the tubular expansion cone 14, respectively, the tubular supportmember 12 and tubular expansion cone 14 are displaced upwardly relativeto the expandable tubular members, 16, 24, and 30, and the tubularmembers, 20, 22, 26, and 28, by applying an upward axial force to theupper end of the tubular support member.

After completing the radial expansion and plastic deformation of thethird expandable tubular member 30, the tubular support member 12 andthe tubular expansion cone 14 are removed from the wellbore 100.

In an exemplary embodiment, as illustrated in FIG. 1 f, the lowercentral portion of the shoe 18 is then removed using a conventionalmilling device.

Thus, during the operation of the system 10, the intermediate nonpre-expanded portions, 16 c, 24 c, and 30 c, of the expandable tubularmembers, 16, 24, and 30, respectively, are radially expanded andplastically deformed by the pressurization of the interior passages, 18a, 16 b, 20 b, 22 b, 24 b, 26 b, 28 b, and 30 b, of the shoe 18, theexpandable tubular member 16, the tubular members, 20 and 22, theexpandable tubular member 24, the tubular members, 26 and 28, and theexpandable tubular member 30, respectively, below the tubular expansioncone 14. As a result, the sealing members, 16 e, 24 e, and 30 e, aredisplaced in the radial direction into engagement with the wellborecasing 104 thereby coupling the shoe 18, the expandable tubular member16, the tubular members, 20 and 22, the expandable tubular member 24,the tubular members, 26 and 28, and the expandable tubular member 30 tothe wellbore casing. Furthermore, as a result, the expandableconnections between the expandable tubular members, 16, 24, and 30, theshoe 18, and the tubular members, 20, 22, 26, and 28, do not have to beexpandable connections thereby providing significant cost savings.Furthermore, in the system 10, the tubular members 20, 22, 26, and 28are interleaved among the expandable tubular members, 16, 24, and 30. Asa result, because only the intermediate non pre-expanded portions, 16 c,24 c, and 30 c, of the expandable tubular members, 16, 24, and 30,respectively, are radially expanded and plastically deformed, thetubular members, 20, 22, 26, and 28 can be conventional tubular membersthereby significantly reducing the cost and complexity of the system 10.Moreover, because only the intermediate non pre-expanded portions, 16 c,24 c, and 30 c, of the expandable tubular members, 16, 24, and 30,respectively, are radially expanded and plastically deformed, the numberand length of the interleaved tubular members, 20, 22, 26, and 28 can bemuch greater than the number and length of the expandable tubularmembers. In an exemplary embodiment, the total length of theintermediate non pre-expanded portions, 16 c, 24 c, and 30 c, of theexpandable tubular members, 16, 24, and 30, is approximately 200 feet,and the total length of the tubular members, 20, 22, 26, and 28, isapproximately 3800 feet. Consequently, in an exemplary embodiment, aliner having a total length of approximately 4000 feet is coupled to awellbore casing by radially expanding and plastically deforming a totallength of only approximately 200 feet.

Furthermore, the sealing members 16 e, 24 e, and 30 e, of the expandabletubular members, 16, 24, and 30, respectively, are used to couple theexpandable tubular members and the tubular members, 20, 22, 26, and 28to the wellbore casing 104, the radial gap between the tubular members,the expandable tubular members, and the wellbore casing 104 may be largeenough to effectively eliminate the possibility of damage to theexpandable tubular members and tubular members during the placement ofthe system 10 within the wellbore casing.

In an exemplary embodiment, after the sealing member 16 e of theexpandable tubular member 16 has been radially expanded into engagementwith the wellbore casing 104, the expandable tubular members, 24 and 30,are radially expanded and plastically deformed by injecting the fluidicmaterial 106 and applying an upward axial force to the tubular supportmember 12 and tubular expansion cone 14. In this manner, radialexpansion and plastic deformation of the expandable tubular members, 24and 30, may be enhanced.

In an exemplary embodiment, after the sealing member 16 e of theexpandable tubular member 16 has been radially expanded into engagementwith the wellbore casing 104, the expandable tubular members, 24 and 30,are radially expanded and plastically deformed by only applying anupward axial force to the tubular support member 12 and tubularexpansion cone 14. In this manner, radial expansion and plasticdeformation of the expandable tubular members, 24 and 30, may beprovided without the further continued injection of the fluidic material106.

In an exemplary embodiment, the pre-expanded ends, 16 a, 16 d, 24 a, 24d, 30 a, and 30 d, of the expandable tubular members, 16, 24, and 30,respectively, and the tubular members, 20, 22, 26, and 28, have outsidediameters and wall thicknesses of 8.375 inches and 0.350 inches,respectively; prior to the radial expansion, the intermediate nonpre-expanded portions, 16 c, 24 c, and 30 c, of the expandable tubularmembers, 16, 24, and 30, respectively, have outside diameters of 7.625inches; the tubular members, 20, 22, 26, and 28, have inside diametersof 7.675 inches; after the radial expansion, the inside diameters of theintermediate portions, 16 c, 24 c, and 30 c, of the expandable tubularmembers, 16, 24, and 30, are equal to 7.675 inches; and the wellborecasing 104 has an inside diameter of 8.755 inches.

In an exemplary embodiment, the pre-expanded ends, 16 a, 16 d, 24 a, 24d, 30 a, and 30 d, of the expandable tubular members, 16, 24, and 30,respectively, and the tubular members, 20, 22, 26, and 28, have outsidediameters and wall thicknesses of 4.500 inches and 0.250 inches,respectively; prior to the radial expansion, the intermediate nonpre-expanded portions, 16 c, 24 c, and 30 c, of the expandable tubularmembers, 16, 24, and 30, respectively, have outside diameters of 4.000inches; the tubular members, 20, 22, 26, and 28, have inside diametersof 4.000 inches; after the radial expansion, the inside diameters of theintermediate portions, 16 c, 24 c, and 30 c, of the expandable tubularmembers, 16, 24, and 30, are equal to 4.000 inches; and the wellborecasing 104 has an inside diameter of 4.892 inches.

In an exemplary embodiment, the system 10 is used to form or repair awellbore casing, a pipeline, or a structural support.

Referring now to FIG. 2, an exemplary embodiment of an expandabletubular member 200 will now be described. The tubular member 200 definesan interior region 200 a and includes a first end 200 b including afirst threaded connection 200 ba, a first tapered portion 200 c, anintermediate portion 200 d, a second tapered portion 200 e, and a secondend 200 f including a second threaded connection 200 fa. The tubularmember 200 further preferably includes an intermediate sealing member200 g that is coupled to the exterior surface of the intermediateportion 200 d.

In an exemplary embodiment, the tubular member 200 has a substantiallyannular cross section. The tubular member 200 may be fabricated from anynumber of conventional commercially available materials such as, forexample, Oilfield Country Tubular Goods (OCTG), 13 chromium steeltubing/casing, or L83, J55, or P110 API casing.

In an exemplary embodiment, the interior 200 a of the tubular member 200has a substantially circular cross section. Furthermore, in an exemplaryembodiment, the interior region 200 a of the tubular member includes afirst inside diameter D₁, an intermediate inside diameter D_(INT), and asecond inside diameter D₂. In an exemplary embodiment, the first andsecond inside diameters, D₁ and D₂, are substantially equal. In anexemplary embodiment, the first and second inside diameters, D₁ and D₂,are greater than the intermediate inside diameter D_(INT).

The first end 200 b of the tubular member 200 is coupled to theintermediate portion 200 d by the first tapered portion 200 c, and thesecond end 200 f of the tubular member is coupled to the intermediateportion by the second tapered portion 200 e. In an exemplary embodiment,the outside diameters of the first and second ends, 200 b and 200 f, ofthe tubular member 200 is greater than the outside diameter of theintermediate portion 200 d of the tubular member. The first and secondends, 200 b and 200 f, of the tubular member 200 include wallthicknesses, t₁ and t₂, respectively. In an exemplary embodiment, theoutside diameter of the intermediate portion 200 d of the tubular member200 ranges from about 75% to 98% of the outside diameters of the firstand second ends, 200 a and 200 f. The intermediate portion 200 d of thetubular member 200 includes a wall thickness t_(INT).

In an exemplary embodiment, the wall thicknesses t₁ and t₂ aresubstantially equal in order to provide substantially equal burststrength for the first and second ends, 200 a and 200 f, of the tubularmember 200. In an exemplary embodiment, the wall thicknesses, t₁ and t₂,are both greater than the wall thickness t_(INT) in order to optimallymatch the burst strength of the first and second ends, 200 a and 200 f,of the tubular member 200 with the intermediate portion 200 d of thetubular member 200.

In an exemplary embodiment, the first and second tapered portions, 200 cand 200 e, are inclined at an angle, α, relative to the longitudinaldirection ranging from about 0 to 30 degrees in order to optimallyfacilitate the radial expansion of the tubular member 200. In anexemplary embodiment, the first and second tapered portions, 200 c and200 e, provide a smooth transition between the first and second ends,200 a and 200 f, and the intermediate portion 200 d, of the tubularmember 200 in order to minimize stress concentrations.

The intermediate sealing member 200 g is coupled to the outer surface ofthe intermediate portion 200 d of the tubular member 200. In anexemplary embodiment, the intermediate sealing member 200 g seals theinterface between the intermediate portion 200 d of the tubular member200 and the interior surface of a wellbore casing 205 after the radialexpansion and plastic deformation of the intermediate portion 200 d ofthe tubular member 200. In an exemplary embodiment, the intermediatesealing member 200 g has a substantially annular cross section. In anexemplary embodiment, the outside diameter of the intermediate sealingmember 200 g is selected to be less than the outside diameters of thefirst and second ends, 200 a and 200 f, of the tubular member 200 inorder to optimally protect the intermediate sealing member 200 g duringplacement of the tubular member 200 within the wellbore casings 205. Theintermediate sealing member 200 g may be fabricated from any number ofconventional commercially available materials such as, for example,thermoset or thermoplastic polymers. In an exemplary embodiment, theintermediate sealing member 200 g is fabricated from thermoset polymersin order to optimally seal the radially expanded intermediate portion200 d of the tubular member 200 with the wellbore casing 205. In severalalternative embodiments, the sealing member 200 g includes one or morerigid anchors for engaging the wellbore casing 205 to thereby anchor theradially expanded and plastically deformed intermediate portion 200 d ofthe tubular member 200 to the wellbore casing.

Referring to FIGS. 3, and 4 a to 4 d, in an exemplary embodiment, thetubular member 200 is formed by a process 300 that includes the stepsof: (1) upsetting both ends of a tubular member in step 305; (2)expanding both upset ends of the tubular member in step 310; (3) stressrelieving both expanded upset ends of the tubular member in step 315;(4) forming threaded connections in both expanded upset ends of thetubular member in step 320; and (5) putting a sealing material on theoutside diameter of the non-expanded intermediate portion of the tubularmember in step 325.

As illustrated in FIG. 4 a, in step 305, both ends, 400 a and 400 b, ofa tubular member 400 are upset using conventional upsetting methods. Theupset ends, 400 a and 400 b, of the tubular member 400 include the wallthicknesses to and t₂. The intermediate portion 400 c of the tubularmember 400 includes the wall thickness t_(INT) and the interior diameterD_(INT). In an exemplary embodiment, the wall thicknesses t₁ and t₂ aresubstantially equal in order to provide burst strength that issubstantially equal along the entire length of the tubular member 400.In an exemplary embodiment, the wall thicknesses t₁ and t₂ are bothgreater than the wall thickness t_(INT) in order to provide burststrength that is substantially equal along the entire length of thetubular member 400, and also to optimally facilitate the formation ofthreaded connections in the first and second ends, 400 a and 400 b.

As illustrated in FIG. 4 b, in steps 310 and 315, both ends, 400 a and400 b, of the tubular member 400 are radially expanded usingconventional radial expansion methods, and then both ends, 400 a and 400b, of the tubular member are stress relieved. The radially expandedends, 400 a and 400 b, of the tubular member 400 include the interiordiameters D₁ and D₂. In an exemplary embodiment, the interior diametersD₁ and D₂ are substantially equal in order to provide a burst strengththat is substantially equal. In an exemplary embodiment, the ratio ofthe interior diameters D₁ and D₂ to the interior diameter D_(INT) rangesfrom about 100% to 120% in order to faciliate the subsequent radialexpansion of the tubular member 400.

In a preferred embodiment, the relationship between the wall thicknessest₁, t₂, and t_(INT) of the tubular member 400; the inside diameters D₁,D₂ and D_(INT) of the tubular member 400; the inside diameterD_(wellbore) of the wellbore casing that the tubular member 400 will beinserted into; and the outside diameter D_(cone) of the expansion conethat will be used to radially expand the tubular member 400 within thewellbore casing is given by the following expression: $\begin{matrix}{{{Dwellbore} - {2*t_{1}}} \geq D_{1} \geq {\frac{1}{t_{1}}\left\lbrack {{\left( {t_{1} - t_{INT}} \right)*D_{cone}} + {t_{INT}*D_{INT}}} \right\rbrack}} & (1)\end{matrix}$where t₁=t₂; andD₁=D₂.

By satisfying the relationship given in equation (1), the expansionforces placed upon the tubular member 400 during the subsequent radialexpansion process are substantially equalized. More generally, therelationship given in equation (1) may be used to calculate the optimalgeometry for the tubular member 400 for subsequent radial expansion andplastic deformation of the tubular member 400 for fabricating and/orrepairing a wellbore casing, a pipeline, or a structural support.

As illustrated in FIG. 4 c, in step 320, conventional threadedconnections, 400 d and 400 e, are formed in both expanded ends, 400 aand 400 b, of the tubular member 400. In an exemplary embodiment, thethreaded connections, 400 d and 400 e, are provided using conventionalprocesses for forming pin and box type threaded connections availablefrom Atlas-Bradford.

As illustrated in FIG. 4 d, in step 325, a sealing member 400 f is thenapplied onto the outside diameter of the non-expanded intermediateportion 400 c of the tubular member 400. The sealing member 400 f may beapplied to the outside diameter of the non-expanded intermediate portion400 c of the tubular member 400 using any number of conventionalcommercially available methods. In a preferred embodiment, the sealingmember 400 f is applied to the outside diameter of the intermediateportion 400 c of the tubular member 400 using commercially availablechemical and temperature resistant adhesive bonding.

In an exemplary embodiment, the expandable tubular members, 16, 24, and30, of the system 10 are substantially identical to, and/or incorporateone or more of the teachings of, the tubular members 200 and 400.

Referring to FIG. 5, an exemplary embodiment of tubular expansion cone500 for radially expanding the tubular members 16, 24, 30, 200 and 400will now be described. The expansion cone 500 defines a passage 500 aand includes a front end 505, a rear end 510, and a radial expansionsection 515.

In an exemplary embodiment, the radial expansion section 515 includes afirst conical outer surface 520 and a second conical outer surface 525.The first conical outer surface 520 includes an angle of attack α₁ andthe second conical outer surface 525 includes an angle of attack α₂. Inan exemplary embodiment, the angle of attack α₁ is greater than theangle of attack α₂. In this manner, the first conical outer surface 520radially overexpands the intermediate portions, 16 c, 24 c, 30 c, 200 d,and 400 c, of the tubular members, 16, 24, 30, 200, and 400, and thesecond conical outer surface 525 radially overexpands the pre-expandedfirst and second ends, 16 a and 16 d, 24 a and 24 d, 30 a and 30 d, 200b and 200 f, and 400 a and 400 b, of the tubular members, 16, 24, 30,200 and 400. In an exemplary embodiment, the first conical outer surface520 includes an angle of attack α₁ ranging from about 8 to 20 degrees,and the second conical outer surface 525 includes an angle of attack α₂ranging from about 4 to 15 degrees in order to optimally radially expandand plastically deform the tubular members, 16, 24, 30, 200 and 400.More generally, the expansion cone 500 may include 3 or more adjacentconical outer surfaces having angles of attack that decrease from thefront end 505 of the expansion cone 500 to the rear end 510 of theexpansion cone 500.

Referring to FIG. 6, another exemplary embodiment of a tubular expansioncone 600 defines a passage 600 a and includes a front end 605, a rearend 610, and a radial expansion section 615. In an exemplary embodiment,the radial expansion section 615 includes an outer surface having asubstantially parabolic outer profile thereby providing a paraboloidshape. In this manner, the outer surface of the radial expansion section615 provides an angle of attack that constantly decreases from a maximumat the front end 605 of the expansion cone 600 to a minimum at the rearend 610 of the expansion cone. The parabolic outer profile of the outersurface of the radial expansion section 615 may be formed using aplurality of adjacent discrete conical sections and/or using acontinuous curved surface. In this manner, the region of the outersurface of the radial expansion section 615 adjacent to the front end605 of the expansion cone 600 may optimally radially overexpand theintermediate portions, 16 c, 24 c, 30 c, 200 d, and 400 c, of thetubular members, 16, 24, 30, 200, and 400, while the region of the outersurface of the radial expansion section 615 adjacent to the rear end 610of the expansion cone 600 may optimally radially overexpand thepre-expanded first and second ends, 16 a and 16 d, 24 a and 24 d, 30 aand 30 d, 200 b and 200 f, and 400 a and 400 b, of the tubular members,16, 24, 30, 200 and 400. In an exemplary embodiment, the parabolicprofile of the outer surface of the radial expansion section 615 isselected to provide an angle of attack that ranges from about 8 to 20degrees in the vicinity of the front end 605 of the expansion cone 6800and an angle of attack in the vicinity of the rear end 610 of theexpansion cone 600 from about 4 to 15 degrees.

In an exemplary embodiment, the tubular expansion cone 14 of the system10 is substantially identical to the expansion cones 500 or 600, and/orincorporates one or more of the teachings of the expansion cones 500and/or 600.

In several alternative embodiments, a conventional rotary expansionsystem such as, for example, those commercially available fromWeatherford International may be substituted for, or used in combinationwith the expansion cones 14, 500, and/or 600 above.

In several alternative embodiments, conventional expansion systems maybe substituted for, or used in combination with the expansion cones 14,500, and/or 600 above.

A system for lining a wellbore casing has been described that includes atubular support member defining a first passage, a tubular expansioncone defining a second passage fluidicly coupled to the first passagecoupled to an end of the tubular support member and comprising a taperedend, a tubular liner coupled to and supported by the tapered end of thetubular expansion cone, and a shoe defining a valveable passage coupledto an end of the tubular liner, wherein the tubular liner includes oneor more expandable tubular members that each include a tubular bodycomprising an intermediate portion and first and second expanded endportions coupled to opposing ends of the intermediate portion, and asealing member coupled to the exterior surface of the intermediateportion, and one or more other tubular members coupled to the expandabletubular members, wherein the inside diameters of the other tubularmembers are greater than or equal to the outside diameter of the tubularexpansion cone. In an exemplary embodiment, the wall thicknesses of thefirst and second expanded end portions are greater than the wallthickness of the intermediate portion. In an exemplary embodiment, eachexpandable tubular member further includes a first tubular transitionarymember coupled between the first expanded end portion and theintermediate portion, and a second tubular transitionary member coupledbetween the second expanded end portion and the intermediate portion,wherein the angles of inclination of the first and second tubulartransitionary members relative to the intermediate portion ranges fromabout 0 to 30 degrees. In an exemplary embodiment, the outside diameterof the intermediate portion ranges from about 75 percent to about 98percent of the outside diameters of the first and second expanded endportions. In an exemplary embodiment, the burst strength of the firstand second expanded end portions is substantially equal to the burststrength of the intermediate tubular section. In an exemplaryembodiment, the ratio of the inside diameters of the first and secondexpanded end portions to the interior diameter of the intermediateportion ranges from about 100 to 120 percent. In an exemplaryembodiment, the relationship between the wall thicknesses t₁, t₂, andt_(INT) of the first expanded end portion, the second expanded endportion, and the intermediate portion, respectively, of the expandabletubular members, the inside diameters D₁, D₂ and D_(INT) of the firstexpanded end portion, the second expanded end portion, and theintermediate portion, respectively, of the expandable tubular members,and the inside diameter D_(wellbore) of the wellbore casing that theexpandable tubular member will be inserted into, and the outsidediameter D_(cone) of the expansion cone that will be used to radiallyexpand the expandable tubular member within the wellbore casing is givenby the following expression:${{{Dwellbore} - {2*t_{1}}} \geq D_{1} \geq {\frac{1}{t_{1}}\left\lbrack {{\left( {t_{1} - t_{INT}} \right)*D_{cone}} + {t_{INT}*D_{INT}}} \right\rbrack}};$

wherein t₁=t₂; and wherein D₁=D₂. In an exemplary embodiment, thetapered end of the tubular expansion cone includes a plurality ofadjacent discrete tapered sections. In an exemplary embodiment, theangle of attack of the adjacent discrete tapered sections increases in acontinuous manner from one end of the tubular expansion cone to theopposite end of the tubular expansion cone. In an exemplary embodiment,the tapered end of the tubular expansion cone includes an paraboloidbody. In an exemplary embodiment, the angle of attack of the outersurface of the paraboloid body increases in a continuous manner from oneend of the paraboloid body to the opposite end of the paraboloid body.In an exemplary embodiment, the tubular liner includes a plurality ofexpandable tubular members, and the other tubular members areinterleaved among the expandable tubular members.

A method of lining a wellbore casing has also been described thatincludes positioning a tubular liner within the wellbore casing, andradially expanding one or more discrete portions of the tubular linerinto engagement with the wellbore casing. In an exemplary embodiment, aplurality of discrete portions of the tubular liner are radiallyexpanded into engagement with the wellbore casing. In an exemplaryembodiment, the remaining portions of the tubular liner are not radiallyexpanded. In an exemplary embodiment, the discrete portions of thetubular liner are radially expanded by injecting a fluidic material intothe tubular liner. In an exemplary embodiment, the tubular linerincludes a plurality of tubular members; and wherein one or more of thetubular members are radially expanded into engagement with the wellborecasing and one or more of the tubular members are not radially expandedinto engagement with the wellbore casing. In an exemplary embodiment,the tubular members that are radially expanded into engagement with thewellbore casing include a portion that is radially expanded intoengagement with the wellbore casing and a portion that is not radiallyexpanded into engagement with the wellbore casing. In an exemplaryembodiment, the tubular liner includes one or more expandable tubularmembers that each include a tubular body comprising an intermediateportion and first and second expanded end portions coupled to opposingends of the intermediate portion, and a sealing member coupled to theexterior surface of the intermediate portion, and one or more othertubular members coupled to the expandable tubular members, wherein theinside diameters of the other tubular members are greater than or equalto the maximum inside diameters of the expandable tubular members. In anexemplary embodiment, the tubular liner includes a plurality ofexpandable tubular members, and the other tubular members areinterleaved among the expandable tubular members.

A system for lining a wellbore casing has also been described thatincludes means for positioning a tubular liner within the wellborecasing, and means for radially expanding one or more discrete portionsof the tubular liner into engagement with the wellbore casing. In anexemplary embodiment, a plurality of discrete portions of the tubularliner are radially expanded into engagement with the wellbore casing. Inan exemplary embodiment, the remaining portions of the tubular liner arenot radially expanded. In an exemplary embodiment, the discrete portionsof the tubular liner are radially expanded by injecting a fluidicmaterial into the tubular liner. In an exemplary embodiment, the tubularliner includes a plurality of tubular members; and wherein one or moreof the tubular members are radially expanded into engagement with thewellbore casing and one or more of the tubular members are not radiallyexpanded into engagement with the wellbore casing. In an exemplaryembodiment, the tubular members that are radially expanded intoengagement with the wellbore casing comprise a portion that is radiallyexpanded into engagement with the wellbore casing and a portion that isnot radially expanded into engagement with the wellbore casing.

An apparatus has also been described that includes a subterraneanformation defining a borehole, a casing positioned in and coupled to theborehole, and a tubular liner positioned in and coupled to the casing atone or more discrete locations. In an exemplary embodiment, the tubularliner is coupled to the casing at a plurality of discrete locations. Inan exemplary embodiment, the tubular liner is coupled to the casing by aprocess that includes positioning the tubular liner within the casing,and radially expanding one or more discrete portions of the tubularliner into engagement with the casing. In an exemplary embodiment, aplurality of discrete portions of the tubular liner are radiallyexpanded into engagement with the casing. In an exemplary embodiment,the remaining portions of the tubular liner are not radially expanded.In an exemplary embodiment, the discrete portions of the tubular linerare radially expanded by injecting a fluidic material into the tubularliner. In an exemplary embodiment, the tubular liner includes aplurality of tubular members; and wherein one or more of the tubularmembers are radially expanded into engagement with the casing and one ormore of the tubular members are not radially expanded into engagementwith the casing. In an exemplary embodiment, the tubular members thatare radially expanded into engagement with the casing comprise a portionthat is radially expanded into engagement with the casing and a portionthat is not radially expanded into engagement with the casing. In anexemplary embodiment, the tubular liner includes one or more expandabletubular members that each include a tubular body comprising anintermediate portion and first and second expanded end portions coupledto opposing ends of the intermediate portion, and a sealing membercoupled to the exterior surface of the intermediate portion, and one ormore other tubular members coupled to the expandable tubular members,wherein the inside diameters of the other tubular members are greaterthan or equal to the maximum inside diameters of the expandable tubularmembers. In an exemplary embodiment, the tubular liner includes aplurality of expandable tubular members, and the other tubular membersare interleaved among the expandable tubular members.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the system 10may be used to form or repair a wellbore casing, an undergroundpipeline, a structural support, or a tubing. Furthermore, the system 10may include one or more expandable tubular members and one or more othertubular members. In addition, the system 10 may include a plurality ofexpandable tubular members, and the other tubular members may beinterleaved among the expandable tubular members.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1-48. (canceled)
 49. A system for lining a wellbore casing, comprising:a support member; an expansion device coupled to an end of the supportmember; and a tubular liner coupled to the expansion device, wherein thetubular liner comprises: one or more expandable tubular members thateach comprise: a first tubular portion, a second tubular portion, and anintermediate tubular portion coupled between the first and secondtubular portions; and a sealing member coupled to the exterior surfaceof the intermediate tubular portion, and wherein the inside diameters ofthe first and second tubular portions are greater than the insidediameter of the intermediate tubular portion.
 50. The system of claim49, wherein the wall thicknesses of the first and second tubularportions are greater than the wall thickness of the intermediate tubularportion.
 51. The system of claim 49, wherein each expandable tubularmember further comprises: a first tubular tapered transitionary portioncoupled between the first tubular portion and the intermediate tubularportion; and a second tubular tapered transitionary portion coupledbetween the second tubular portion and the intermediate tubular portion,and wherein angles of inclination of the first and second taperedtubular transitionary portions relative to the intermediate tubularportion ranges from greater than 0 to about 30 degrees.
 52. The systemof claim 49, wherein the outside diameter of the intermediate tubularportion ranges from about 75 percent to about 98 percent of the outsidediameters of the first and second tubular portions.
 53. The system ofclaim 49, wherein the burst strength of the first and second tubularportions is substantially equal to the burst strength of theintermediate tubular portion.
 54. The system of claim 49, wherein theratio of the inside diameters of the first and second tubular portionsto the interior diameter of the intermediate tubular portion ranges fromgreater than 100 to about 120 percent.
 55. The system of claim 49,wherein the relationship between the wall thicknesses t₁, t₂, andt_(INT) of the first tubular portion, the second tubular portion, andthe intermediate tubular portion, respectively, of the expandabletubular members, the inside diameters D₁, D₂ and D NT of the firsttubular portion, the second tubular portion, and the intermediatetubular portion, respectively, of the expandable tubular members, andthe inside diameter D_(wellbore) of the wellbore casing that theexpandable tubular members will be inserted into, and the outsidediameter D_(cone) of the expansion device that will be used to radiallyexpand the expandable tubular members within the wellbore casing isgiven by the following expression:${{{Dwellbore} - {2*t_{1}}} \geq D_{1} \geq {\frac{1}{t_{1}}\left\lbrack {{\left( {t_{1} - t_{INT}} \right)*D_{cone}} + {t_{INT}*D_{INT}}} \right\rbrack}};$wherein t₁=t₂; and wherein D₁=D₂.
 56. The system of claim 49, whereinthe expansion device comprises a plurality of adjacent discrete taperedsections.
 57. The system of claim 56, wherein an angle of attack of theadjacent discrete tapered sections increases in a continuous manner fromone end of the expansion device to the opposite end of the expansiondevice.
 58. The system of claim 49, wherein the expansion devicecomprises a paraboloid body.
 59. The system of claim 58, wherein anangle of attack of the outer surface of the paraboloid body increases ina continuous manner from one end of the paraboloid body to the oppositeend of the paraboloid body.
 60. The system of claim 49, wherein thetubular liner comprises a plurality of expandable tubular members andone or more other tubular members, and wherein the other tubular membersare interleaved among the expandable tubular members.
 61. A system forlining a wellbore casing, comprising: an expansion device; and a tubularliner coupled to the expansion device, wherein the tubular linercomprises: one or more expandable tubular members that each comprise: afirst tubular portion, a second tubular portion, and an intermediatetubular portion coupled between the first and second tubular portions;and a sealing member coupled to the exterior surface of the intermediatetubular portion, and wherein the inside diameters of the first andsecond tubular portions are greater than the inside diameter of theintermediate tubular portion.
 62. The system of claim 61, wherein theburst strength of the first and second tubular portions is substantiallyequal to the burst strength of the intermediate tubular portion.
 63. Thesystem of claim 61, wherein the wall thicknesses of the first and secondtubular portions are greater than the wall thickness of the intermediatetubular portion.
 64. The system of claim 61, wherein each expandabletubular member further comprises: a first tubular tapered transitionaryportion coupled between the first tubular portion and the intermediatetubular portion; and a second tubular tapered transitionary portioncoupled between the second tubular portion and the intermediate tubularportion, and wherein angles of inclination of the first and secondtapered tubular transitionary portions relative to the intermediatetubular portion ranges from greater than 0 to about 30 degrees.
 65. Thesystem of claim 61, wherein the outside diameter of the intermediatetubular portion ranges from about 75 percent to about 98 percent of theoutside diameters of the first and second tubular portions.
 66. Thesystem of claim 61, wherein the ratio of the inside diameters of thefirst and second tubular portions to the interior diameter of theintermediate tubular portion ranges from greater than 100 to about 120percent.
 67. The system of claim 61, wherein the relationship betweenthe wall thicknesses t₁, t₂, and t_(INT) of the first tubular portion,the second tubular portion, and the intermediate tubular portion,respectively, of the expandable tubular members, the inside diametersD₁, D₂ and D_(INT) of the first tubular portion, the second tubularportion, and the intermediate tubular portion, respectively, of theexpandable tubular members, and the inside diameter D_(wellbore) of thewellbore casing that the expandable tubular members will be insertedinto, and the outside diameter D_(cone) of the expansion device thatwill be used to radially expand the expandable tubular members withinthe wellbore casing is given by the following expression:${{{Dwellbore} - {2*t_{1}}} \geq D_{1} \geq {\frac{1}{t_{1}}\left\lbrack {{\left( {t_{1} - t_{INT}} \right)*D_{cone}} + {t_{INT}*D_{INT}}} \right\rbrack}};$wherein t₁=t₂; and wherein D₁=D₂.
 68. A liner for lining a wellborecasing, comprising: a first tubular portion, a second tubular portion,and an intermediate tubular portion coupled between the first and secondtubular portions; and a sealing member coupled to the exterior surfaceof the intermediate tubular portion, wherein the inside diameters of thefirst and second tubular portions are greater than the inside diameterof the intermediate tubular portion.
 69. The liner of claim 68, whereinthe burst strength of the first and second tubular portions issubstantially equal to the burst strength of the intermediate tubularportion.
 70. The liner of claim 68, wherein the wall thicknesses of thefirst and second tubular portions are greater than the wall thickness ofthe intermediate tubular portion.
 71. The liner of claim 68, whereineach expandable tubular member further comprises: a first tubulartapered transitionary portion coupled between the first tubular portionand the intermediate tubular portion; and a second tubular taperedtransitionary portion coupled between the second tubular portion and theintermediate tubular portion, and wherein angles of inclination of thefirst and second tapered tubular transitionary portions relative to theintermediate tubular portion ranges from greater than 0 to about 30degrees.
 72. The liner of claim 68, wherein the outside diameter of theintermediate tubular portion ranges from about 75 percent to about 98percent of the outside diameters of the first and second tubularportions.
 73. The liner of claim 68, wherein the ratio of the insidediameters of the first and second tubular portions to the interiordiameter of the intermediate tubular portion ranges from greater than100 to about 120 percent.
 74. The liner of claim 68, wherein therelationship between the wall thicknesses t₁, t₂, and t_(INT) of thefirst tubular portion, the second tubular portion, and the intermediatetubular portion, respectively, of the expandable tubular members, theinside diameters D₁, D₂ and D_(INT) of the first tubular portion, thesecond tubular portion, and the intermediate tubular portion,respectively, of the expandable tubular members, and the inside diameterD_(wellbore) of the wellbore casing that the expandable tubular memberswill be inserted into, and the outside diameter D_(cone) of theexpansion device that will be used to radially expand the expandabletubular members within the wellbore casing is given by the followingexpression:${{{Dwellbore} - {2*t_{1}}} \geq D_{1} \geq {\frac{1}{t_{1}}\left\lbrack {{\left( {t_{1} - t_{INT}} \right)*D_{cone}} + {t_{INT}*D_{INT}}} \right\rbrack}};$wherein t₁=t₂; and wherein D₁=D₂.
 75. An expansion device, comprising: aparaboloid body.
 76. A system for lining a wellbore casing, comprising:an expansion device coupled to an end of the support member; and atubular liner coupled to the expansion device, wherein the tubular linercomprises: one or more expandable tubular members that each comprise: afirst tubular portion, a second tubular portion, and an intermediatetubular portion coupled between the first and second tubular portions;and a sealing member coupled to the exterior surface of the intermediatetubular portion, wherein the inside diameters of the first and secondtubular portions are greater than the inside diameter of theintermediate tubular portion, and wherein the expansion device comprisesa plurality of adjacent discrete tapered sections.
 77. The system ofclaim 76, wherein an angle of attack of the adjacent discrete taperedsections increases in a continuous manner from one end of the expansiondevice to the opposite end of the expansion device.
 78. A system forlining a wellbore casing, comprising: an expansion device coupled to anend of the support member; and a tubular liner coupled to the expansiondevice, wherein the tubular liner comprises: one or more expandabletubular members that each comprise: a first tubular portion, a secondtubular portion, and an intermediate tubular portion coupled between thefirst and second tubular portions; and a sealing member coupled to theexterior surface of the intermediate tubular portion, wherein the insidediameters of the first and second tubular portions are greater than theinside diameter of the intermediate tubular portion, and wherein theexpansion device comprises a paraboloid body.
 79. The system of claim78, wherein an angle of attack of the outer surface of the paraboloidbody increases in a continuous manner from one end of the paraboloidbody to the opposite end of the paraboloid body.
 80. A system for lininga wellbore casing, comprising: an expansion device coupled to an end ofthe support member; and a tubular liner coupled to the expansion device,wherein the tubular liner comprises: one or more expandable tubularmembers that each comprise: a first tubular portion, a second tubularportion, and an intermediate tubular portion coupled between the firstand second tubular portions; and a sealing member coupled to theexterior surface of the intermediate tubular portion, wherein the insidediameters of the first and second tubular portions are greater than theinside diameter of the intermediate tubular portion, wherein the tubularliner comprises a plurality of expandable tubular members and one ormore other tubular members, and wherein the other tubular members areinterleaved among the expandable tubular members.
 81. A tubular linersystem, comprising: a plurality of expandable tubular members that eachcomprise: a first tubular portion, a second tubular portion, and anintermediate tubular portion coupled between the first and secondtubular portions, the inside diameters of the first and second tubularportions being greater than the inside diameter of the intermediatetubular portion; a sealing member coupled to the exterior surface of theintermediate tubular portion; and a plurality of other tubular membersinterleaved among the expandable tubular members.